Food product which artificially has been given a cell-like structure by coextrusion of several components, and method and apparatus for manufacturing such food product

Abstract

Two or more different materials such as food material are co-extruded through adjacent orifices of an extruder. The flows of the two materials are cut in a direction transverse to the flow to form segments of flow. These segments are interspersed so as to join upstream and downstream of each segment of first material to a segment of a second material. Generally two rows of joined segmented flows are extruded side by side. Preferably between the tow rows is formed a boundary cell wall which usually is transformed to a harder material after extrusion. Cell walls of the harder material may surround, in two or three dimensions, cells of softer of foamed material. The apparatus and method to provide the food product having the cell like structure is particularly useful for producing confectionery products formed of chocolate, marzipan or dough materials.

1. A three-dimensional food product, elongated in at least the z-dimension and consisting of at least two components A and B which have been coextruded to become interspersed with each other, in which a plurality of cells of component A are surrounded at least in the xz plane by at least one component B which forms cell walls surrounding the A component, wherein said B component is a solid (including a viscoelastic solid) at 20° C., the cells of component A are arranged in at least two mutually distinct rows extending generally in the z direction, each said row of cells being separated from each adjacent row by a generally continuous in the z direction boundary cell wall of said B component, and either a) component A is a fluid having no compressional yield point at 20° C. or is a solid having plastic, pseudoplastic or viscoelastic consistency at 20° C. and a compressional yield point (YPB 20 ), at 20° C. which is less than 0.5× the compressional yield point of B at 20° C. (YP B20 ), or b) component A is an expanded material containing at least 50% by volume gas. 
     
     
       2. A product according to  claim 1  having two generally opposite xz faces and in which each cell of component A extends in a generally y direction substantially from a position at least adjacent to one xz face of the food product to a position at least adjacent to the other xz face. 
     
     
       3. A product according to  claim 1  in which there are two different B components B 1  and B 2  and the boundary cell wall is formed of said first component B 1  and the product has bridging cells walls branching from said boundary cell wells and extending at least part way in a generally x direction towards the adjacent boundary cell wall, the bridging cell walls being form at least in part of component B 2 . 
     
     
       4. A product according to  claim 1  in which the components B 1  and B 2  have different yield points at 20° C. 
     
     
       5. A product according to  claim 4  in which the yield point of component B 1  at 20° C. (YP B1(20 )) is in the range of 0.1 to 0.5 of the yield point of B 2  at 20° C. (YPBP(20). 
     
     
       6. A product according to  claim 1  which has two generally opposite xz faces and each of the cells of component A extends part way between said two xz faces with at least two of said cells spanning the distance between the two xz faces, all of the cells being separated from one another in the y-direction, and B components are arranged between adjacent cells of component A and are separated from one another generally in the y direction to form cell walls around each component A cell, so that the A component cells are substantially enveloped by cell walls of component B. 
     
     
       7. A product according to  claim 6  having two different B components B 1  and B 2  in which the B component between adjacent cells of the A component separated in the y-direction comprises component B 1 . 
     
     
       8. A product according to  claim 1  in which there are bridging cell walls branching from said boundary cell walls separating adjacent rows of A component cells and extending at least part way in a generally x direction toward an adjacent boundary cell wall and between cells of A component in said rows, and said boundary cell walls and said bridging cell walls are formed of the same B component. 
     
     
       9. A product according to  claim 1 , characterized in that any attenuation in the thickness of said bridging cell walls in the vicinity of a boundary cell wall has a local thickness generally not any thinner than {fraction (1/15)} of the thickest portion thereof. 
     
     
       10. A product according to  claim 8  in which said boundary walls of B-component extend in waved or zig-zagging manner about a plane extending in the zy plane. 
     
     
       11. A product according to  claim 1  which has bridging cell walls formed of a component B branching from said boundary cell walls and extending at least part way in a generally x direction toward an adjacent boundary cell wall and the bridging cell walls which branch off from the boundary cell walls, considered in a yz plane, branch off substantially perpendicularly to the boundary cell wall at the branching points thereof. 
     
     
       12. A product according to  claim 2  which further comprises surface boundary walls of a component B extending substantially continuously generally at least adjacent to each xz face thereof. 
     
     
       13. A product according to  claim 1  in which each boundary cell wall separating adjacent rows of cells of said component A is substantially planar. 
     
     
       14. A product according to  claim 1  in which the cross section of said cells of component A in the xz plane has an average dimension in the z-direction in the range of 0.5 to 10 mm. 
     
     
       15. A product according to  claim 1  in which the average cross-sectional area of said cells of component A in the xz plane is in the range of 0.5-100 mm 2 . 
     
     
       16. A product according to  claim 1  in which the average separation between adjacent rows of said cells of said component A is in the range 1-25 mm. 
     
     
       17. A product according to  claim 16  in which the boundary cell walls of said component B separating adjacent rows of said cells of component A have a minimum thickness in the x direction in the range 5-50% of the average separation between adjacent rows. 
     
     
       18. A product according to  claim 11  in which the bridging cell walls have a minimum thickness of 0.1 mm. 
     
     
       19. A product according to  claim 1  wherein component A in the final form of the product at 20° C. is fluid. 
     
     
       20. A product according to  claim 1  wherein component A in the final form of the product at 20° C. is a plastic, pseudoplastic or viscoelastic material having a compressional yield point, YP A  lower than 1000 g cm −2 . 
     
     
       21. A product according to  claim 20  wherein component A comprises a blend of solid particles selected from the group consisting of short fibres, nut- grain- or shell-pieces, film-pieces or flakes, with a water based solution or gel. 
     
     
       22. A product according to  claim 20  wherein component A comprises a blend of solid particles selected from the group consisting of short fibres, nut-, grain-, or shell-pieces, film-pieces or flakes with an oil. 
     
     
       23. A product according to  claim 1  wherein component B is in the form of a gel. 
     
     
       24. A product according to  claim 1  in which component a including a component B reinforced with solid particles selected from the group consisting of short fibres, or grain-, shell- or film-pieces or flakes, has a yield point YP B , of at least 200 g cm 2 . 
     
     
       25. A product according to  claim 1  wherein component B is comprised of fat, oil or wax with flavoring additives. 
     
     
       26. A product according to  claim 1 , wherein component B comprises protein. 
     
     
       27. A product according to  claim 1 , wherein component B is a microporous agglomerate of particles containing water in the pores, said particles being selected from the group consisting of short fibres or grain-, shell- or film-pieces or flakes and are bonded together by micro-stands of a polymer selected from the group consisting of coagulation gluten or a natural or synthetic rubber as produced by coagulation of a latex. 
     
     
       28. A product according  claim 1  wherein component B comprises a gel of a polymer selected from the group consisting of carbohydrates or carbohydrate related compounds. 
     
     
       29. A product according to  claim 1  wherein component B comprises a polymer and in the boundary cell walls of said polymer B extending in a generally z direction the molecules thereof are molecularly oriented generally in the z direction. 
     
     
       30. A product according to  claim 1  wherein component A is a juice containing dissolved sugar and is in form of a flowable soft gel or thick liquid thickened with a thickening agent. 
     
     
       31. A product according to  claim 1  wherein component A is a juice in the form of a soft gel or a thick liquid thickened with a thickening agent and contains hydrolysed proteins to in sufficient amount to impart taste and nutritional value. 
     
     
       32. A product according to  claim 1  wherein component A contains a pulp of subdivided protein fibres or film. 
     
     
       33. A product according to  claim 1  wherein component A is a cultured milk product. 
     
     
       34. A product according to  claim 1  wherein component A is marzipan. 
     
     
       35. A product according to  claim 1  wherein component A comprises a meat paste. 
     
     
       36. A product according to  claim 1  wherein the A component contains gas dispersed therethrough. 
     
     
       37. A product according to  claim 36  which is a bread or cake and component A comprises expanded and baked starch and B comprises protein. 
     
     
       38. A product according to  claim 36  wherein component B comprises cheese. 
     
     
       39. A product according to  claim 1  wherein component A has two different components, A 1  and A 2 . 
     
     
       40. A product according to  claim 39  in which component A 1  comprises a waterbased solution or gel forming a matrix for solid particles, and A 2  comprises fat or oil forming a matrix for solid particles. 
     
     
       41. A food product which is a three dimensional solid at 20° C. and is elongated in at least the z-dimension and consists of at least two components A and B which have different visual appearances and have been coextruded to intersperse segments of A and segments of B, wherein each B component is a solid at 20° C. and each A component is a solid at 20° C., the segments of component A are arranged in at least two mutually distinct rows extending generally in the z-direction, and the rows of segments of component A and interspersed segments of component B are visible at at least one surface of the product extending generally in a xz plane. 
     
     
       42. A product according to  claim 41  in which the segments of component A and segments of component B are attenuated in their minimum thickness adjacent their ends as compared to their thickness at points intermediate their ends and in which the segments are dragged out during their coextrusion so as to form an acute angle of less than about 45° with the z-direction in the xz plane. 
     
     
       43. A product according to  claim 41  in which component A and component B are selected from the group consisting of the following combinations:
 a. dark chocolate/light chocolate  
 b. chocolate/marzipan  
 c. chocolate/caramel  
 d. two differently coloured edible gums or fruit gels.  
 
     
     
       44. A method of manufacturing by coextrusion of a plurality of extrudable edible components in an extrusion die a solid food product in which the components are extruded in a z-direction from the extrusion die and exit therefrom, and in which at least one extrudable component A′ is formed into a flow through a channel and an extrudable component B′ is formed in a flow through a channel, the flow of B′ being in generally an x direction transverse to said z direction adjacent the flow of A′, in which after exiting from said die, the flows of A′ and B′ are regularly divided generally in said x-direction by a dividing member to form at least two rows of flows of A′ and B′ separated in the x-direction, in each of which rows the flows of A′ and B′ are segmented in the z direction with a segment of flow of B′ being joined upstream and downstream to each segment of flow of A′, whereby B′ segments are interposed between adjacent A′ segments in the z direction and in which adjacent rows are joined to one another along their yz faces, and wherein after the joining of the segmental flows B′ is transformed to a normally solid material having a compressional yield point which is at least twice that of B′. 
     
     
       45. A method according to  claim 44  in which after the segments of flows are joined, the material A′ is expanded to at least twice its original volume, or material A′ is treated to reduce its yield point, if material A′ is solid, or its apparent viscosity, if material A′ is liquid, by at least one-half. 
     
     
       46. A method according to  claim 44 , wherein the extrusion is carried out at an elevated temperature and material B′ is treated by cooling. 
     
     
       47. A method according to  claim 44  wherein material B′ is treated for form a coagulate or gel. 
     
     
       48. A method according to  claim 47  wherein material B′ is heated to form the coagulate or gel. 
     
     
       49. A method according to  claim 47  wherein material B′ normally has a continuous, firm gel structure and prior to its coextrusion is converted into extrudable form by disruption to a finely divided condition, and after the end of the coextrusion, material B′ is treated to reestablish its continuous firm structure. 
     
     
       50. A method according to  claim 47  wherein material B′ is treated by chemical reaction to form the coagulate or gel. 
     
     
       51. A method according to  claim 50  wherein a gelling reagent or coagulant is incorporated into material B′ prior to the extrusion process and the rate of gelation or coagulation is retarded to delay gelation or coagulation until after the completion of said joining of said flows. 
     
     
       52. A method according to  claim 51  in which said reagent or coagulant is incorporated into solid particles suspended in material B′. 
     
     
       53. A method according to  claim 51  in which material B′ is adapted to undergo gel formation or coagulation by enzymatic action and the gel formation or coagulation is carried out by means of an enzyme. 
     
     
       54. A method according to  claim 47  wherein material B′ is adapted to undergo gel formation or coagulation by action of a reactant and said reactant is incorporated in the material A′, thereby gradually migrating into material B′ when materials A′ and B′ are brought together in the coextrusion die. 
     
     
       55. A method according to  claim 44  in which both material A′ and material B′ are each formed into at least two flows separated from one another in the x direction and in which flows of material B′ are partially interposed between adjacent flows of material A′. 
     
     
       56. A method of coextruding at least two extrudable materials A′ and B′ in an extrusion die which comprises the steps of supplying at least one material A′ from a reservoir therefor and advancing the same by extrusion pressure as a flow through one extrusion channel and out of an exit from the channel end, and supplying at least one material B′ from a reservoir therefor and advancing the same by extrusion pressure as a narrow flow through a separate extrusion channel and out of an exit from the channel end; dividing each of the flows of materials A′ and B′ not prior to the respective channel exits into segments of the respective extrudates by a dividing member therefor, each said dividing member moving relative to the corresponding channel exit to traverse the entire channel exit; and controlling the flows of both materials A′ and B′ out of the extrusion channel exit to cause said flows to be intermittent in nature in synchronism with the movement of said dividing members. 
     
     
       57. The method of  claim 56  wherein said flows of said materials A′ and B′ are controlled to cause the respective materials to flow from the corresponding channel exits when said dividing members are in said first and second positions but not when said dividing members are moving across said channel exits. 
     
     
       58. The method of  claim 56  in which said flows of said materials A′ and B′ are controlled to take place intermittently by periodically applying and releasing said extrusion pressure to the respective materials in the corresponding channels. 
     
     
       59. The method of  claim 56  in which said flows of said materials A′ and B′ are controlled to take place intermittently by periodically blocking and opening the channel exits to prevent said material, from exiting therefrom. 
     
     
       60. A method according to  claim 56  including the additional step of joining together the segments of said materials A′ and B′ after their formation by said dividing member so that segments of material A′ alternate with segments of material B′. 
     
     
       61. A method according to  claim 57  in which the relative movement of said dividing members with respect to said channel exits creates a plurality of adjacent rows of segments of material A′ and segments of material B′ joined to the segments of material A′ in said rows. 
     
     
       62. A method according to  claim 44  which comprises the further step of collecting the rows of segments of materials A′ and B′ after they are joined, in a collection chamber in the form of a sheet. 
     
     
       63. A method of manufacturing by coextrusion in sheet, ribbon or filament form of a food product which is normally solid at 20° C. and is comprised of at least two components A and B in segment form, wherein segments of component B are in contact with segments of component A, which comprises extruding flows of an extrudable component A pre-cursor A′ and of an extrudable component B pre-cursor B′ from separate orifices of an extrusion die, subdividing each of said flows into segments and combining said subdivided flows in rows with the segments of pre-cursor B′ generally alternating with segments of pre-cursor A′ and, after extrusion, converting said pre-cursor B′ to a solid material B, in which extrudable pre-cursor B′ is adapted to be rendered normally solid by coagulation or gel formation and a coagulant or gelling reagent is incorporated in pre-cursor A′ whereby when said segments of pre-cursor B′ are in contact with segments of pre-cursor A′, said pre-cursor B′ is gelled or coagulated by said reagent. 
     
     
       64. A method according to  claim 63  an which said pre-cursor B′ is adapted to undergo gelling or coagulation by the action of an enzyme and an enzyme is incorporated in said pre-cursor A′. 
     
     
       65. A method according to  claim 64  in which pre-cursor B′ comprises a protein and said enzyme is a protease. 
     
     
       66. An apparatus suitable for carrying out a process according to  claim 44 , comprising an extrusion die having channels for flow therethrough of at least two different relatively soft extrudable materials, said channels ending in orifices for exit in generally one direction of said materials from the channels, said channels being separated from one another in a direction generally transverse to said one direction, dividing members capable of moving in said generally transverse direction across the orifices to divide the flows into segments arranged in at least two adjacent rows extending generally in said one direction, and means for combining said rows of segments into a unitary product, and comprising further means for subjecting said product to conditions to convert at least one of the materials in the product from its relatively soft extrudable state to a relatively hard solid state. 
     
     
       67. Apparatus suitable for carrying out the process of  claim 56 , comprising an extrusion die having channels terminating in exit orifices through which at least two different extrudable materials may flow, said orifices being arranged generally in a row and separated from one another generally in the direction of said row, means for causing the materials to pass through the channels and out of said orifices, dividing members which are capable of intermittent movement relative to said orifices in generally said same direction across the orifices to divide the flows of materials therethrough, and means for controlling the movement of the dividing members and said means for causing the materials to pass through the channels and out of said orifices so that relative movement of the dividing members with respect to said orifices takes place intermittently and said materials are passed out of said orifices while relative movement between the dividing members and the orifices is stopped. 
     
     
       68. Apparatus as in  claim 67  wherein said means for causing said material to pass through said channels and out of the orifices thereof comprises a pressure member for each channel operable intermittently to exert and release extrusion pressure upon the material in such channel. 
     
     
       69. Apparatus as in  claim 67  wherein said channels have entrance openings for introduction of the respective materials therein and further comprising reservoirs for the respective materials in communication with said entrance openings to deliver the materials therefrom to said openings and non-return valves between said entrance openings and said reservoirs to prevent return flow of materials to said reservoirs when said pressure members exert extrusion pressure upon the materials in said channels while allowing flow from the reservoirs to said openings when said extrusion pressure is released. 
     
     
       70. Apparatus as in  claim 67  wherein said means for controlling the driving of said materials through said channels and out of the orifices comprises valve means associated with each channel orifice and operable to alternatively block and open said orifices for passage of said materials therethrough.